Foldable assembly of like size and shape structural members, foldable for handling, packaging, shipping, and storage, and unfolded and utilized as principal members of structures

ABSTRACT

Principal members of structures are manufactured as foldable assemblies of like size and shape structural members, foldable for handling, packaging, shipping, and storage, and unfolded into their respective principal member configurations. Each like size and shape structural member has its opposite end surfaces formed on a sixty degree bias, whereby one longitudinal edge surface is longer than the other opposite edge surface, thereby creating opposite trapezoidal side surfaces. Each of these members has two spaced holes formed along its centerline, and each of these holes is equally spaced from a respective bias end. Regarding relative design dimensions, the respective longitudinal centerline length of each like size and shaped structural member is given the formula dimension, L, then the space between holes, X, is equal to 0.464 L, and the space from each hole to the centerline end, Y, is equal to 0.268 L. Using fasteners passing through respective aligned holes, these like size and shape structures are arranged as pivotal members, in two adjacent parallel planes, each plane staying within the thickness of the thickness size of one like size and shape structural member, to become, when unfolded, a complete principal member of a structure, in reference to 360 degrees, either in a vertical plane or a horizontal plane.

CROSS REFERENCE

This is a Divisional Application based on the original application Ser.No. 08/072,468, filed on Jun. 4, 1993, now U.S. Pat. No. 5,363,626.

BACKGROUND

Pre-manufactured structural building components to be unfolded atbuilding sites to become principal structural members of buildings havebeen provided previously. For example:

In U.S. Pat. No. 3,375,624 of 1968, Tom T. Mikulin illustrated anddescribed his structural members which included lazy tong components.His members are expandable from a contracted condition, occupying verylittle space, to a greatly enlarged condition having a great deal ofstrength;

In U.S. Pat. No. 3,557,500 of 1971, Messrs. Schmidt and Rial disclosedtheir foldable structures. They provide structural units, used withsimilar units, to form structures of different shape and size. Theirstructural units are readily erected, readily folded, and readilycollapsed;

In U.S. Pat. No. 3,559,353 of 1971, Gordon C. Partridge illustrated anddescribed his collapsible building structures, which are erected easily,and also easily collapsed for movement to another site, or for storage,or for transportation. His structures have at least two latticeworkunits, in a parallel relationship. Each unit has links pivotallyconnected to be expanded from a collapsed arrangement to an operativeformation of a beam or a truss;

In U.S. Pat. No. 3,729,877 of 1973, Raymond L. Hall disclosed hisfolding truss, wherein his main beam member in a fully unfolded openedposition is arranged in a straight line. In its folded position hisfolding truss is compacted into an accordion style. In addition to themain beam members he uses a series of support arms. They are pivotallymounted on pins secured to the mid-portions of the main beam members.When the main beam members are aligned, the support members are disposedin a zigzag pattern relative to the axis of the main straight beam;

In U.S. Pat. No. Re 31,565 of 1984, Bryan J. Beaulieu illustrated anddescribed his portable shelter. It has a pair of collapsible framemembers at the ends thereof. Each of those collapsible frame membersincluded a braced lazy-tong structure;

In U.S. Pat. No. 4,689,932 of 1987, Theodore R. Ziegler disclosed hisportable shelter assemblies. Their framework is formed by a series ofend-interconnected modules, each defining a separate arch portion,extending in different directions. Each module is formed of elongatedstruts capable of being expanded into arched three dimensional form andcollapsed into bundled form; and

In U.S. Pat. No. 5,024,031 of 1991, Charles Hoberman illustrated anddescribed his radial expansion and retraction truss structures. Theyprovided self-supporting structures that maintain their overall curvedgeometry, as they expand or collapse in a synchronized manner. In oneembodiment, the radial expansion and retraction truss appears as aniris-type retractable structure. Its center retracts toward itsperimeter, which remains a nearly constant size.

These examples of pre-manufactured structural building components to beunfolded at building sites are all recognized for their respectivemerits. However there remains a need for yet another one which iseconomically manufactured, handled, stored, shipped, and erected incombination with other standard building materials.

SUMMARY

There are many needs for erecting structures in small, medium, and largesizes more conveniently. Often these needs involve circumstances, whichpreferably require efficient and convenient pre-manufacturing, handling,packaging, shipping, and storage. The principal members of suchstructures, when being finally assembled, must be quickly and easilyassembled into very strong structural members. These needs extend, forexample, from the mass type marketing of garden houses to beconveniently assembled at their places of use, to shipping buildingcomponents to Alaska to be assembled during limited warmer weather timeson ground areas, often referred to as tundra, which in turn ofteninvolve permafrost ground conditions.

Therefore, to provide the principal members of such structures, foldableassemblies of like size and shape structural members arepre-manufactured. They are folded at time of manufacture for handling,packaging, shipping, and storage, and unfolded at the erection site tobe utilized as the principal members of structures.

Each like size and shape structural member of a particular designedrespective overall size principal member of a structure, has itsopposite end surfaces formed on a sixty degree bias, whereby onelongitudinal edge surface is longer than the opposite edge surface.Therefore, each of these members, when observed from either side,appears as a trapezoidal side surface structure.

Along a longitudinal centerline of each of these trapezoidal sidesurfaces, two spaced through holes are made, based on the formuladimension, L, for the length along this centerline. The space betweenthe holes, X, is equal to 0.464L, and the space from each hole to thecenterline end, Y, is equal to 0.268L.

When fastener assemblies are inserted through these spaced holes, as theside by side like size and shape structural members are pivotallysecured together, then a foldable assembly is completed and compactlyarranged in a planar configuration. These foldable assemblies, inreference to 180 degrees when unfolded, become, for example, the trussesof buildings. When more like members are included in these foldableassemblies, in reference to 360 degrees when unfolded, become an entirecircumferential principal structural member, optionally arranged inselected designs in either vertical or horizontal planes.

By way of example, these foldable assemblies of like size and shapestructural members, when combined with other members selected fromavailable standard materials, are used in structures such as gardenhouses, greenhouses, storage buildings, carports, garages, boatshelters, military field shelter-housing-storage, temporary housing indisaster areas, Arctic and Antarctic temporary housing for survey crewsand scientists, covers for walkways, silos, hot tubs, liquid holdingtanks, liquid spill dams, and sludge lagoons.

DRAWINGS

The foldable assembly of like size and shape structural members,foldable for handling, packaging, shipping, and storage, and unfoldedand utilized, as principal members of structures, is illustrated in thedrawings in two basic embodiments, and also in embodiments, in which oneor the other of the two basic embodiments is utilized with other likebasic embodiments, as principal members of structures. In the drawings:

FIG. 1 is a perspective view of a building frame, which includes threespaced like foldable assemblies of like size and shape structuralmembers, serving as roof trusses, when arranged in respective verticalplanes;

FIG. 2 is a perspective view of one of the three spaced like foldableassemblies of like size and shape structural members, serving as a rooftruss when assembled, as illustrated in FIG. 1, and when folded forhandling, shipping and storage, and in this embodiment two of theotherwise, like size and shape structural members, are made longer toalso serve as columns;

FIG. 3 is a top view of a structure without a roof installed, havingfully surrounding frames made of like size and shape structural members,each serving as a principal member and arranged in a horizontal plane,and showing how some other structural members, serving as wall members,are arranged with them;

FIG. 4 is a perspective view of the structure shown in FIG. 3, having atop about to be rotated in place, to illustrate how the fullysurrounding frames are spaced and connected to some other structuralmembers, serving as wall members;

FIG. 5 is an enlarged view of the one of the three spaced like foldableassemblies of like size and shape structural members serving as rooftrusses, as illustrated in FIGS. 1 and 2, with two of the structuralmembers optionally being extended to serve also as columns;

FIG. 6 is a top view of the foldable assembly, shown in FIG. 5, when itis folded for handling, packaging, shipping, and storage;

FIG. 7 is a partial side view of some of the like size and shapestructural members, illustrated in FIG. 5, showing how they are beingassembled after being unfolded, from their folded together arrangement,shown in FIG. 6, into their assembled arrangement, shown in FIG. 5;

FIG. 8 is a partial exploded view, to illustrate the fasteners and thelike spacing of the holes to receive these fasteners, the like size andshape of the structural members, with the exception of two of them inthis embodiment, which are made longer to serve also as columns, andportions of spaced roof stringers, which are notched to fit over thesestructural members arranged as a roof truss;

FIG. 9 is a perspective view of the interior of a structure, arranged asshown in FIG. 1, and being used as a garden house, with the roof andportions of the walls being made of clear materials;

FIG. 10 is a perspective view of a building which could be used, forexample, as a military field shelter for housing and/or storage, inwhich the roof trusses are foldable assemblies of like size and shapestructural members;

FIG. 11 is a perspective view of a vehicle garage, in which the rooftrusses are foldable assemblies of like size and shape structuralmembers;

FIG. 12 is a perspective view of a somewhat open shelter, in which theroof trusses are foldable assemblies of like size and shape structuralmembers, and also shown is the optional use of foundation blocks, withonly one being shown at one corner;

FIG. 13 is a perspective view of a structure holding liquid, such as ahot tub, in which the fully surrounding frame, arranged in spacedhorizontal planes, are made of like size and shape structural members,and showing how some other structural members, serving as wall members,are arranged within the fully surrounding frames, and also showing aliquid containing liner;

FIG. 14 is a side elevational view, partially in section, illustrating atank holding a liquid such as oil, having three spaced fully surroundingframes arranged in horizontal planes, which are made of like size andshape structural members, and showing wall members arranged within thesefully surrounding frames, and also showing how a surrounding safetybasin is provided to become effective if the tank overflows and/orleaks, and larger diameter fully surrounding frames are arrangedconcentrically with the tank to support liquid tight materials servingas a bottom and wall of this safety basin;

FIG. 15 is a perspective view of a building formed in a optional Tconfiguration, and using throughout, spaced fully surrounding framesarranged in vertical planes, and they are all made from foldableassemblies of like size and shape structural members, which in turnsupport the longitudinal structural members;

FIG. 16 is a schematic layout of the centerlines of the like size andshape structural members arranged together continuously in a designatedplane, with general formula letters and the relative numerals set forthto illustrate how the sizes of these structural members are determined,and where the fastener holes are located; and

FIG. 17 is a view of one major surface of one like size and shapestructural member, showing the centerline, the fastener holes, the sixtydegree formed ends, and the formula letters and relative numerals.

DESCRIPTIONS OF PREFERRED EMBODIMENTS

Introduction

Like size and shape structural members are conveniently and economicallymanufactured for convenient assembly with other like members in selectedembodiments of foldable assemblies. They are so folded for handling,packaging, shipping, and storage. At an erection site, they are unfoldedand utilized as the principal members of structures. These foldableassemblies in respective embodiments later become the principal members,for example, as building trusses, in reference to their 180 degreeunfolding, and as entire circumferential principal frames, optionallyarranged in selected buildings in either vertical or horizontal planes,in reference to their 360 degree unfolding.

When these trusses and frames are combined with other members selectedfrom available standard materials, the overall structures may be gardenhouses, greenhouses, storage buildings, carports, garages, boatshelters, military field shelter-housing-storage buildings, temporaryhousing in disaster areas, Arctic and Antarctic temporary housing forsurvey crews and scientists, covers for walkways, silos, hot tubs,liquid holding tanks, liquid spill dams, and sludge lagoons.

The Like Size and Shape Structure Member Available in Various OverallSizes for a Particular Embodiment in which They Are All Alike in Sizeand Shape

Each like size and shape structural member 20 to be used in a respectiveoverall size principal member 22, has its opposite end surfaces 24, 26,formed on a sixty degree bias or angle. Therefore one edge 28 of itslongitudinal opposite edge surfaces is longer than the other oppositeedge surface 30. Each member 20, then has opposite trapezoidal sidesurfaces 32, 34.

Also each like size and shape structural member 20 has two spaced holes36, 38, of like diameter, formed along its longitudinal centerline. Eachof these holes 36, 38, is equally spaced from a respective bias end 24,26, in reference to the longitudinal centerline.

Regarding relative design dimensions, the respective longitudinalcenterline length of each like size and shape structural member is giventhe formula dimension, L. Then the space, X, between the holes 36, 38,is equal to 0.464L, and the space, Y, from each hole to the centerlineend is equal to 0.268L.

Using fasteners 40 passing through respective aligned holes 36, 38,these like size and shape structural members 20, are arranged as pivotalmembers, in two adjacent parallel planes 42, 44. Each plane of pivotalmembers stays within the thickness of the thickness size of one likesize and shape structural member 20. Upon assembling a principalstructural member 22, at the outset in reference to three like size andshaped structural members 20, the first and third are in one adjacentplane 42 and the second is in the other adjacent plane 44. Thisrelationship of up and down members 20 continues in reference to the twoadjacent planes 42, 44 as the assembly is undertaken.

The resulting foldable assemblies 46 include sufficient like size andshape structural members 20, for example, to become, when unfolded, atruss 48 arranged in a vertical plane, in reference to one hundred andeighty degrees. If more members 20 are added, a foldable assembly 46becomes, when unfolded, a complete frame 50, in reference to threehundred and sixty degrees to be used in either a vertical plane or ahorizontal plane, as a principal member 22 of a structure. At all timesthe members of the foldable assemblies when in use are in compression.

Like Size and Shape Structural Members Supplemented by Terminal MembersServing Also as Columns

In reference to 180 degrees, when a particular foldable assembly 46 isto be unfolded to become a truss 48, then preferably the terminalmembers 54, 56 are longer than the other like size and shape structuralmembers 20, and serve as columns 54, 56, having squared lower ends 58,60. This truss-column embodiment 62 is illustrated in FIGS. 1, 3, and 5through 12.

Although not illustrated, the extra length portions 64 could be suppliedseparately for connection to like size and shape structural members tocreate the columns 54, 56. This connection procedure would be used whenthe initial shipping size restrictions would eliminate the initialcolumn lengths.

However, if the full length columns 54, 56 may be shipped, then foldedassembly 46 will be premanufactured, as shown in FIGS. 2 and 6. At thebuilding site, the folded assembly 46, will be unfolded, as illustratedin FIGS. 2, 5, 7, and 8.

The 180 degree embodiment of the truss, with or without columns, is keptin compression throughout all of its members. The transverse centerlinedimension between the vertical members which are secured, per se, or asextended columns is 1.732L.

They are secured in their compression insuring positions by using across bracing compression member, and/or by using foundation members towhich they are well secured.

Like Size and Shape Structural Members, with and Without TerminalMembers Serving Also as Columns, Serve as Respective Overall SizePrincipal Members of Many Types of Buildings

Garden houses and/or greenhouses, or other shelters using the like sizeand shape structural members, with terminal members serving also ascolumns, are particularly illustrated in FIGS. 1, 2, and 5 through 9. Agarden house 68 shown in FIG. 1, at the outset, may have additions, asshown in FIG. 9, to become a greenhouse 70.

For example, three folded assemblies 46, as shown in FIGS. 2 and 6, areunfolded as shown in FIG. 7 to become the truss-column embodiments 62,illustrated in FIGS. 1, 2, 5, and 9. The premanufacture assembly of thefoldable assembly 46, in respect to the holes 36, 38, and the fasteners40, is indicated in FIG. 8. Also shown in FIG. 8, are stringers 74 orroof beams 74. These stringers 74 may be premanufactured and includedwith the folded assemblies 46, or they may be obtained later.Preferably, they will have receiving notches 76 to interfit with thetruss-column embodiments 62. Thereafter a fastener 78 will be used tocomplete their securement.

As indicated in FIGS. 1 and 9, other portions of the garden house 68 orthe greenhouse 70 will be derived from available products, referred toas standard market products. For example, as shown in FIGS. 1 and 9, twoby four framing members 80, plywood panels 82, a door 84, clear oropaque plastic cover 86, cabinets 88, benches 90, floor 92, light 94,etc. may all be used to complete the designed building, utilizing thelike size and shape structural members 20, arranged in theirtruss-column embodiment 62.

Other designed buildings are illustrated in FIGS. 10, 11, and 12, whichwill include the like size and shape structural members 20, andoptionally use the extra length portions 64 to create the columns 54,56. Then the standard materials will be more durable in particularreference to the weather coverings. The building 96 illustrated in FIG.10 is suitable for housing people. It will be insulated and there willbe windows 98 and a door 84. The building 102 illustrated in FIG. 11 issuitable to completely enclose, for example, a vehicle. At the entrydoor 104, a parking-serving ramp 106 is formed using concrete. Thebuilding 108 shown in FIG. 12 serves as or like a carport, providingoverhead shelter. Optionally, standard foundation blocks 100 could beused in reference to all these buildings. If they are not used, thenlower transverse members 112 must be used between all columns 54, 56, tofirmly complete the overall positioning of all the like size and shapestructural members 20 of these truss-column embodiments 62.

Like Size and Shape Structural Members Arranges Continuously, inReference to 360 Degrees, and Positioned in Horizontal Planes, Serve asRespective Overall Size Principal Structural Members of VariousStructures Having Various Purposes

Structures such as silos 114, shown in FIG. 4, are made using the likesize and shape structural members 20, which are continuously arranged,in reference to 360 degrees, as illustrated in FIGS. 3 and 4. After thelast fastener 40 is installed, the resulting circular-frame embodiment116 becomes a very rigid, strong, respective overall sized principalframe member 22. Other portions of this silo 114 are made of standardbuilding materials, such as boards 118, concrete base 120, and roof 122.

Also liquid-tight liners 124 are included in these structures utilizingthe circular-frame embodiments 116. In FIG. 13, a tank structure 126 isillustrated, serving as a hot tub 126, when such a liner 124 isincluded. Also liquid-tight liners 124 are used in larger tanks 128, asshown in FIG. 14. If the liquids pumped into and out of such largertanks 128, are, for example, like oil, in respect to avoiding and/orcontaining spills, then a surrounding catch or containment basin 130 isprovided. The raised walls 132 of the basin 130, serving as the spillboundary 132, have circular-frame embodiments 116 included, to supportthe expanded liquid-tight liner 124.

This arrangement of the containment basin 130 is also used where themain liquid tank is made of metal or plastic. The circular-frameembodiments 116 made of like size and shape structural members 20 servevery well with the expanded liquid-tight liner 124 in defining andmaintaining the raised walls 132, of the basin 30, which serve as thespill boundary 132.

Like Size and Shaped Structural Members Arranged Continuously, inReference to 360 Degrees, and Positioned in Vertical Planes, Serve asRespective Overall Size Principal Structural Members of VariousStructures Having Various Purposes

Structures such as living quarters 134 or storage volumes 134,illustrated in FIG. 15, to be used, for example, in the Arctic,Antarctic, tundra, and permafrost areas, are provided. These structures134 used any place where foundations are not provided, or cannot beprovided, by virtue of having their circular-frame embodiments 116included in the overall structure of a building 134, provide excellentenclosures to be used for many purposes. The interiors are arranged toserve as living quarters, and/or to provide weatherproof shelter forequipment, etc.

The Basic Design Considerations in Reference to the Like Size and ShapeStructural Members

A schematic line diagram is presented in FIG. 16 to illustrate thederivation of the formulae-dimensions, and in FIG. 17 these dimensionsare specifically indicated on one like size and shape structural member20. The longitudinal centerline length of a member 20 is designated asL. It is equal to the radius of a circle passing through the pairs ofbias opposite end surfaces 24, 26, where they bear against one another.This length L, and the radius, are also equal to the chord length. 1 Thelength L, In respect to where the holes 36, 38 are located, is used inthe formulae-dimensions, by designating space, Y, between these holes,as being 0.4641016L, i.e. called 0,464L, and by designating the spaces,X, between each hole 36 or 38 and the end of the members 20 at theircenterlines, as being 0.2679492L, i.e. called 0.268L.

Buildings and other structures of reasonable sizes to be used for manypurposes are designed by first considering how large each like size andshape structural member 20 must be to create the right size respectiveoverall size principal member 22 in a respective embodiment thereof, toserve with others of the like respective embodiment, when spaced apartand supported relative to one another, to provide the main overall frameof the intended structure.

I claim:
 1. A foldable assembly of like size and shape structuralmembers, foldable for handling, packaging, shipping, and storage, andunfolded and utilized, with each member being in compression, asprincipal members of structures, to be arranged either in a verticalplane, or in a horizontal plane, comprising:a. twelve structural membersof equal overall width, thickness, and length, the length being measuredalong the longitudinal centerline, where in:each of the twelvestructural members has their opposite end surfaces formed on a 60 degreebias, whereby one longitudinal edge surface of each of the twelvestructural members is longer than the other opposite longitudinal edgesurface, thereby creating opposite trapezoidal side surfaces, and eachof the twelve structural members has two spaced holes positioned on thelongitudinal centerline, and each of the holes is respectively equallyspaced inwardly from the nearest biased opposite end surface; and b.fastener assemblies passing through respective aligned holes ofrespective interconnecting groups of three of the structural members,and being secured; whereby two of the three structural members arepositioned in one plane, and the remaining one of the three structuralmembers is positioned in an adjacent parallel plane, resulting in thetwelve structural members being connected together within the twoadjacent parallel planes using the fastener assemblies; and thereafterthe twelve structural members, after the removal of one fastenerassembly, are pivoted together, in one direction, into a side by sideconvenient non-use compacted storage, handling, and transporting,configuration, and pivoted apart, in the opposite direction, into an endfor end useful expanded structural configuration, wherein oppositelypositioned end surfaces, formed on a 60 degree bias, are in an abuttingrelationship, and the foldable assembly is ready for use in the 360degree configuration, when the previously removed one fastener assemblyis reinserted.
 2. A foldable assembly of like size and shape structuralmembers, as claimed in claim 1, spaced apart with a selectable quantityof like foldable assemblies to serve as spaced apart main wall framesarranged in respective horizontal planes.
 3. A foldable assembly of likesize and shape structural members, as claimed in claim 2, comprising, inaddition, vertical side by side members, extending between the likefoldable assemblies serving as the spaced apart main wall framesarranged in respective horizontal planes, to complete an encirclingcontinuous vertical wall structure.
 4. A foldable assembly of like sizeand shape structural members, as claimed in claim 3, comprising, inaddition, a liquid confining lining vertically supported by the spacedapart foldable assemblies forming a secondary cylindrical liquidreceiving volume, adapted to encircle a tank of smaller diameter holdingany liquid, serving as a primary liguid receiving volume, to be able tocapture any spillage or leakage occurring in respect to an encircledsmaller diameter tank to be located within the space defined by thevertical side by side members.
 5. A foldable assembly of like size andshape structural members, as claimed in claim 3, comprising, inaddition, bottom structure extending below the vertical side by sidemembers.
 6. A foldable assembly of like size and shape structuralmembers, as claimed in claim 5, comprising, in addition, a liquidconfining lining positioned within the space defined by vertical side byside members and over the bottom structure, extending below the verticalside by side members, thereby forming a cylindrical liquid receivingvolume.
 7. A foldable assembly of like size and shape structuralmembers, as claimed in claim 5, comprising, in addition, top structureextending across the vertical side by side members.
 8. A foldableassembly of like size and shape structural members, as claimed in claim7 comprising, in addition, a liquid confining lining positioned withinthe area defined by the vertical side by side members forming a primarycylindrical liquid receiving volume that is ready to receive a liquid.9. A foldable assembly of like size and shape structural members, asclaimed in claim 8, comprising, in addition, a spaced surroundingsecondary cylindrical liquid receiving volume of greater diameter thanthe primary cylindrical liquid receiving volume spaced away from andsurrounding the primary liquid receiving to capture any spillage orleakage of liquid from the primary cylindrical liquid volume if filledwith a liquid, comprising in addition:a. larger spaced apart foldableassemblies, of like size and shape structural members spaced apart withat least one other like larger assembly; b. vertical side by sidemembers extending between these larger spaced apart foldable assemblies;and c. a liquid confining lining, vertically supported by these largerspaced apart foldable assemblies, and completing the forming of thisgreater diameter secondary cylindrical liquid receiving volume.
 10. Afoldable assembly of like size and shape structural members, as claimedin claim 1, spaced apart with a selectable quantity of like foldableassemblies to serve as spaced apart frames of a building in respectivevertical planes.
 11. A foldable assembly of like size and shapestructural members, spaced apart with a selectable quantity of likefoldable assemblies to serve as spaced apart frames of a building inrespective vertical planes, as claimed in claim 10, comprising, inaddition:stringer members spaced apart and connecting the spaced apartfoldable assemblies of like size and shape structural members, therebycompleting the overall main frame of a building.
 12. A foldable assemblyof like size and shape structural members and stringers, as claimed inclaim 11, comprising, in addition:Wall boards secured to the overallmain frame of a building; Roofing materials secured to the overall mainframe of a building; Flooring materials secured to the overall mainframe of a building; An access door secured to the overall main frame ofa building, to complete an overall building structure.